Simulation of Variational Compliant Assemblies with Shape Errors Based on Morphing Mesh Approach

Variation analysis of assemblies is a strategic task in many industrial applications. Parts manufactured through plastic deformation processes exhibit appreciable shape deviations from the nominal geometry due mainly to spring-back phenomena. When these parts are assembled, initial shape deviations at part level highly influence the final assembly shape. This work focuses on the modeling and simulation of shape errors in order to perform variation analysis of compliant assemblies. The aim is to simulate variational shape of parts according to a small number of control points chosen on the part geometry through a morphing mesh procedure. These points are typically related to measurement or inspection points of manufactured parts. From the mesh model of parts, mesh nodes are moved by applying the morphing procedure. In particular, in order to assure control points belong to the “perturbed” shape, a linear-constrained approach is adopted. The so-morphed parts are used to accomplish the variational assembly analysis following the classical place, clamp, fasten, and release cycle. In order to achieve statistical results, Monte Carlo simulation is performed: a set of control points driving the perturbed parts is generated at each iteration; these parts are then assembled and results are stored. Numerical results are compared with ones coming from commercial software that uses a linear approach based on the sensitivity matrix.